Analysis of constant tension stress and wear of 12×37 WS multi-strand wire rope

Under heavy-duty and long-stroke operating conditions, multi-strand wire ropes demonstrate excellent performance due to their complex spatial structure; however, this complexity also presents challenges in analyzing their stress distribution and wear behavior. In this study, a mathematical model of a 12× 37 WS multi-strand steel wire rope under both straight and bending state is established based on the Frenet frame. Using this model, the contact and bending stresses between strands are calculated under a tensile load of 6 t. Next, the lay lengths of the inner, middle and outer strands are treated as variables, and their influence on the contact stress is studied, providing guidance for optimizing the structural parameters of multi-strand wire ropes. A finite element model of the rope is then established in SolidWorks, and its mechanical performance is verified through simulation using ANSYS Workbench. Finally, based on theoretical calculations and finite element analysis, it is concluded that the outermost wires are more susceptible to breakage due to wear under constant tension. Additionally, stress levels increase in strands closer to the core. Therefore, a design recommendation is proposed: increasing the diameter of the core strands and reducing that of the outer strands can effectively reduce the breakage rate and enhance rope durability.